Gas turbine engine and composite parts

ABSTRACT

High strength, fracture tough, high temperature oxidatively stable, gas turbine engine core engine components are described made of silicon carbide fiber reinforced ceramic matrix or silicon carbide fiber reinforced glass matrix material. A gas turbine engine containing core engine components as above described is also disclosed.

This is a division of copending application Ser. No. 459,029 filed onJan. 18, 1983 now U.S. Pat. No. 4,626,461 12/2/86.

TECHNICAL FIELD

The field of art to which this invention pertains is gas turbineengines, and specifically core engine components.

BACKGROUND ART

The cost, reliability and performance of gas turbine engines is stronglyinfluenced by the high temperature materials used in their construction.Current aircraft, missile, ground based vehicle and ship propulsion gasturbines, as well as stationary power generation turbines all use metalsuperalloys to provide needed high temperature performance. Used inpolycrystalline or single crystal forms, these metals also imposeseveral important penalties on the overall gas turbine. These alloys arehigh density metals and thus they contribute to overall engine weightand penalize the engine thrust to weight ratio. The densities of themost significant elements used in these alloys are as follows: nickel8.90 gm/cm³ ; chromium 7.19 gm/cm³ ; columbium 7.19 gm/cm³ ; cobalt 8.9gm/cm³ ; and iron 7.87 gm/cm³.

This high density in rotating parts is also a major cause of highstresses generated during engine operation. These stresses limit rotorspeeds and particularly limit the fatigue life of high temperaturediscs.

These elements are very costly and, in many cases, are available onlyfrom limited sources of supply. As such Co, Cb and less abundantly usedelements are referred to as "strategic elements" whose availability intimes of peak demand or disrupted supply may be in question.

At very high temperatures these metal superalloys are severely limiteddue to their propensity to creep under applied stress. Current attemptsto increase engine efficiency have caused the operating temperatures tobe increased beyond those sustainable by these metals alone. Hence theyrequire cooling by low temperature air which is forced through passagesin the blades. This is done at penalty to overall engine efficiency.

Attempts have been made to overcome these deficiencies through the useof ceramic materials such as silicon carbide and silicon nitride. Theseceramics are desirable in that they are capable of operating attemperatures well above those of metal superalloys and they are alsomuch lower in density (e.g. 3.2 gm/cm³). These attempts, however, havebeen hampered in that these ceramic materials are not fracture tough.They fail readily in the presence of stress concentrations and serviceinduced impact damage.

Another attempt to develop high temperature gas turbine materials hascentered on carbon fiber reinforced carbon matrix composites. Thesematerials provide two major advantages over the above metals andceramics. First, they are very low in density (2. gm/cm³) and secondlythey maintain strength and toughness to extremely high temperatures.Unfortunately carbon is easily decomposed by oxidation at elevatedtemperatures in a gas turbine and the utility of these materials is thushinged on the development of coatings and oxidation inhibitors. Becauseof the extreme thermal fluctuations in a gas turbine the development ofthese necessary oxidation preventors has been severely limited. Inaddition, their reliability under stressful operating conditions orduring in-service impact damage is extremely questionable. Theirfabrication cost is also quite high due to the lengthy high temperatureprocesses required to form their matrix from organic precursors.

DISCLOSURE OF INVENTION

The present invention is directed to a solution to the use ofnon-metallic composites in a gas turbine engine, which composites canwithstand the high temperatures produced in such engine and stillmaintain their high strength and oxidative stability. The solution tothis problem is the use of fracture tough silicon carbide fiberreinforced ceramic or silicon carbide fiber reinforced glass with hightemperature strength, high temperature oxidation stability, and goodheat insulating properties as gas turbine engine components.

One aspect of the invention includes the use of components comprising amultilayered-fiber reinforced ceramic made up of a plurality of ceramiclayers, each layer reinforced with a plurality of unidirectional,continuous length silicon carbide fibers, each layer having an axialflexural strength greater than 70,000 psi and a high fracture toughness,exemplified by a critical stress intensity factor greater than 10×10³psi (inch)^(1/2).

Another aspect of the invention includes the use of componentscomprising silicon carbide fiber reinforced borosilicate glass withflexural strengths above about 60,000 psi maintainable at temperaturesup to about 600° C.

Another aspect of the invention includes the use of componentscomprising silicon carbide fiber reinforced high silica content glasswith flexural strengths above about 60,000 psi maintainable attemperatures up to about 1150° C.

Another aspect of the invention includes the use of componentscomprising silicon carbide fiber reinforced aluminosilicate glass withflexural strengths above about 75,000 psi maintainable at temperaturesup to about 700° C.

Another aspect of the invention includes the use of componentscomprising discontinuous silicon carbide fibers laid up in substantiallyin-plane random orientation in a glass matrix having strength andfracture toughness properties greater than that of the glass matrix evenat elevated temperatures, e.g. in excess of 300° C. and even in excessof 500° C.

Another aspect of the invention includes the use of componentscomprising discontinuous silicon carbide fibers laid up in substantiallyin-plane random orientation in a ceramic matrix, having strength andfracture toughness properties greater than that of the ceramic matrixeven at elevated temperatures, e.g. in excess of 800° C., and even inexcess of 1000° C.

Another aspect of the invention includes a gas turbine engine containingcore engine components made of the above recited composite materials.

The foregoing, and other features and advantages of the presentinvention, will become more apparent in light of the followingdescription and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows in cross-section an actual uniaxial silicon carbide fiberreinforced glass-ceramic matrix composite component according to thepresent invention.

FIG. 2 shows in cross-section an actual multiaxial silicon carbide fiberreinforced glass-ceramic matrix composite component according to thepresent invention.

FIG. 3A shows flexural strength data for a borosilicate glass compositecomponent reinforced with silicon carbide yarn according to the presentinvention.

FIG. 3B shows flexural strength data for a borosilicate glass compositecomponent reinforced with large diameter silicon carbide monofilamentsaccording to the present invention.

FIG. 4 shows flexural strength data for a high silica content glasscomposite component according to the present invention.

FIG. 5 shows flexural strength data for an aluminosilicate glasscomposite component according to the present invention.

FIG. 6 shows flexural strength data for lithium aluminosilicateglass-ceramic components reinforced with silicon carbide fibersaccording to the present invention.

FIG. 7 shows fracture toughness data for lithium aluminosilicateglass-ceramic components reinforced with silicon carbide fibersaccording to the present invention.

FIG. 8 shows a top view in cross-section of an actual discontinuoussilicon carbide fiber reinforced glass-ceramic matrix compositecomponent according to the present invention.

FIG. 9 shows a fracture surface of an actual discontinuous siliconcarbide fiber reinforced glass-ceramic matrix composite componentaccording to the present invention.

FIGS. 10A and B show an augmentor divergent seal test component beforeand after actual testing in an augmentor duct.

FIG. 11 shows blades, vanes and seals according to the presentinvention.

FIG. 12 shows augmentor flaps and seals according to the presentinvention.

FIG. 13 shows combustor liner segment panels according to the presentinvention.

BEST MODE FOR CARRYING OUT THE INVENTION

A glass, which can be converted to a ceramic, is the preferred matrixmaterial to form the composite components of the present invention.During composite densification the matrix is retained in the glassystate, thus avoiding fiber damage and promoting densification under lowapplied pressure. After densification to the desired fiber plus matrixconfiguration, the glassy matrix can be converted to the crystallinestate, the degree and extent of crystallization being controlled by thematrix composition and heat treatment schedule employed. A wide varietyof glasses can be used in this manner, however, a strict limitation onthe amount and activity of titanium present in the glass is ofcontrolling importance. Accordingly, if titania nucleating agents areused, they must be inactivated or kept below one percent by weight. Thiscan be accomplished by simply substituting another nucleating agent suchas zirconia for the conventional titania. However, in any case it isnecessary to either eliminate or mask the effects of the titania on thesilicon carbide fiber to attain a composite with the improved propertiesdisclosed. This problem is believed attributable to the reactivity ofthe titanium to the silicon carbide fiber. And while conventionallithium aluminosilicate is the preferred glass ceramic, otherconventional glass ceramics such as aluminosilicate, magnesiumaluminosilicate, and combinations of the above can be used as long asthe ceramic matrix material is titanium free. By titanium free is meantthat the composition contains less than about 1% by weight titanium oradditional components which either mask or inactivate the reactivity ofthe titanium toward the SiC fibers. It has also been found that thereactivity of the titanium and its adverse composite effects can belessened by a combination of decreased titania nucleating agentconcentration and lower hot pressing temperatures--e.g., a glass ceramiccomposition with less than 2% by weight titania, hot pressed attemperatures below about 1100° C. And, as stated above, ZrO₂ is apreferred substitute for the titania nucleating agent in amounts up toabout 5% by weight, producing no adverse effects on the compositeproperties. Other nucleating agents may also be successful substitutesfor the titania. It should also be noted that in general the startingglass ceramic material can be obtained in the glass state in powderform. If however, the ceramic material is obtained in crystalline form,it will be necessary to melt the material to form it into the glassystate, solidify it and subsequently crush it into powder form,preferably about -325 mesh. An important part of the invention is toselect glass ceramic matrix material such as that described above whichcan be densified (in combination with the SiC fibers) in the glassystate with a viscosity low enough to permit complete densification withsubsequent transformation into a substantially complete crystallinestate providing a composite with a use temperature in excess of 1000° C.It is also possible to convert the starting crystalline powder to theglassy state during preheat treatment prior to application of pressurefor densification.

If the component temperature will be kept below 1000° C., a glass matrixconsisting of a high silica content glass, aluminosilicate, orborosilicate composition may be utilized. The glass matrix materialshould also be titanium free, such as Corning #7740 borosilicate glass,available from Corning Glass Works. Note commonly assigned U.S. Pat.Nos. 4,314,852 and 4,324,843 the disclosures of which are incorporatedby reference.

The fiber reinforcement for the glass or glass-ceramic matrix is a hightemperature stable, oxidation resistant material and particularlysilicon carbide fibers. While any silicon carbide fiber with therequisite strength can be used with the ceramic matrix, a multifilamentsilicon carbide yarn with an average filament diameter up to 50 micronsis preferred and yarn with average filament diameter of 5-15 micronsespecially preferred. Nippon Carbon Co. of Japan produces such a yarnwith about 250 fibers per tow and an average fiber diameter of about 10microns. The average strength of this fiber is approximately 2000 MPa(300,000 psi), and it has a use temperature of up to 1500° C. The yarnhas a density of approximately 2.7 gm. per cc and an elastic modulus ofapproximately 221 GPa (32×10⁶ psi).

Several different techniques may be employed in making the desiredcomponent. The first comprises drawing a continuous length ofreinforcing fiber through a slurry of glass powder mixed with a liquidbinder, drying the impregnated fibers, in the form of a tape on a drum,and laying up the resulting fiber tape into a predetermined structuralshape, and then hot pressing it into its final form, note U.S. Pat. Nos.4,314,852 and 4,324,843 cited above.

Another method comprises preparing a mixture of glass powder and choppedfibers or whiskers at elevated temperatures and injecting this mixtureinto a mold of complex shape and then hot pressing into the finalproduct. Note copending, commonly assigned U.S. patent application Ser.No. 381,805 filed May 25, 1982, the disclosure of which is incorporatedby reference.

A third method comprises weaving the fibers or aligning them into a moldcavity in a particular shape or orientation, then introducing the glassmatrix in molten form into the mold such that it Q surrounds and bondsthe fibers. Note copending, commonly assigned U.S. patent applicationSer No. 381,801 filed May 25, 1982 the disclosure of which isincorporated by reference.

Any one of these methods (and any other suitable method) is satisfactoryand the one selected depends on the particular properties desired of thefinal structure.

As stated above, the glass and glass-ceramic constituents are generallyobtained in powder form (preferably about -325 mesh) in the glassy state(noncrystalline form) and are combined in this powder state with thesilicon carbide fibers by hot press consolidation. In the case of theceramic, after densification the composite is held for a time and at atemperature sufficient to transform the noncrystalline ceramic into thecrystalline state by controlled nucleation and growth of the appropriatecrystalline phases. The ceramic or glass composite components arepreferably formed by laying up layers containing continuous siliconcarbide fibers and the powdered ceramic or the powdered glass. Thearticles formed are then hot pressed at elevated temperatures to formthe composite components. The processing parameters and composition ofthe material can vary widely depending on component designconsiderations. The preferred method for forming the articles of thepresent invention is by hot pressing the mixture of silicon carbidefibers and noncrystalline ceramic powder or glass as mentioned above.This method gives particular design flexibility in orienting the fibers,and sheets formed by such method are particularly adapted to hotpressing into desired shapes. An exemplary method comprises continuouslyunwinding a tow of silicon carbide fibers (yarn) from a spool at amoderate rate of speed and passing such fibers through a slip of thepowdered ceramic or powdered glass, solvent and plasticizer toimpregnate the two. The impregnated fibers are then rewound onto alarger rotating spool. An exemplary slip composition may be composed of40 gm. of powdered glass or powdered ceramic and 780 ml of propanol. Analternative composition may comprise 100 gm. of the glass, 200 ml ofwater, and 100 ml of a latex binder such as Rhoplex®. Rhoplex® is aresin suspension or dispersion marketed by Rohm and Haas, Philadelphia,Pa. Excess glass or ceramic and solvent can be removed by pressing asqueegee against the drum as it winds. Preferably the ground ceramic orglass is sized so that 90% of it passes through a -325 mesh sieve. Thethus impregnated tape is then dried either at ambient temperature orwith a radiant heat source to remove solvent. Where an organic binder orother higher melting organic adjuvant has been utilized, it may benecessary to fire the tape at somewhat elevated temperatures to burn outthe organic materials prior to hot-pressing.

Following impregnation, the fiber is removed from the drum and cut intostrips to conform to the dimensions of the article to be fabricated. Thefibers are then laid up in alternating ply stacks in any sequencedesired, e.g., each layer unidirectional, alternating plies of 0° and90°, or 0°/30°/60°/90°, 0°/±45°/90°, etc. In a key processing step theassembled composite is then hot pressed either under vacuum or underinert gas such as argon in metal dies coated with colloidal boronnitride or graphite dies sprayed with boron nitride powder at pressuresof 6.9-13.8 MPa (1000-2000 psi) and temperatures of 1100°-1500° C. Timeof hot pressing will vary depending on composite makeup but generallywill be accomplished between about 1 minute and 1 hour. Additional glassor ceramic also in powder form may be inserted between each layer as itis laid. SiC fiber loading in the composite is preferably about 15% toabout 70% by volume. The mold can also be vibrated to ensure uniformdistribution of the ceramic powder or glass powder over the laid fibersurfaces. In the case of the ceramic, processing by starting with thematrix material in the glassy state to permit composite densification byhot pressing, followed by converting the ceramic into the crystallinestate largely contributes to the superior properties of the resultingcomposite. If after hot pressing any significant portion of the ceramicmatrix material is found to be in the glassy state, further heattreatment may be necessary to substantially completely crystallize thematrix for optimum high temperature performance. And although it ispreferred to have the ceramic matrix material in the fully ceramicstate, acceptable composite properties are attainable even if some ofthe ceramic matrix is retained in the composite in the glassy state,e.g. up to 25% by weight.

Based on the composition of the matrix material, the particular fiberreinforcement, and the process of forming the composite, an article withexceptional high strength, fracture toughness, and oxidation resistanceespecially at high temperatures is obtained. Each fiber reinforced layerof the ceramic composite component regardless of the number of layers ororientation has an axial flexural strength greater than 70,000 psi andin some instances greater than 100,000 psi. As for fracture toughness,each layer has a critical stress intensity factor greater than 10×10³(inch)^(1/2). This is clearly superior to any known ceramic matrixcomposite currently available, especially with the low density andoxidation resistance at high temperatures exhibited by the composites ofthe present invention. An indication of this thermal resistance can beseen from the data in Table I.

                  TABLE I                                                         ______________________________________                                        Bend Strength (3-pt) in Ar vs.                                                Temperature for SiC Yarn/Lithium Aluminosilicate                              Composites (50 Volume Percent SiC).                                                     Bend Strength (10.sup.3 psi)                                                  Unidirectional  0°/90° Cross-                         Temp. °C.                                                                        Composite       plied Composite                                     ______________________________________                                         20        90             50                                                   600      100             60                                                   800      120             70                                                  1000      140             70                                                  1100       90             70                                                  1200       40             40                                                  ______________________________________                                    

From Table I, it can be seen that the ceramic composite components ofthe present invention exhibit excellent flexural strengths in a hightemperature environment well in excess of 1000° C. It is also felt thatbased on the type of matrix employed, these strengths can be maintainedover 1300° C. It should be noted that while each individual layer willhave an axial flexural strength greater than 70,000 psi the overallcomposite could have a flexural strength of a lesser value. A uniaxiallyfiber oriented composite would have an overall axial flexural strengthgreater than 70,000 psi, however, while each individual layer in a0°/90° multiaxially oriented lay-up of individual fiber layers wouldhave an axial flexural strength greater than 70,000 psi, the compositewould have a flexural strength of greater than 35,000 psi because halfthe fibers would not be in the principal test direction. However, suchcomposite would have better overall strength and impact resistance than,say a totally uniaxially oriented composite because of the multiaxialorientation of the fibers. Such multiaxially oriented fiber compositescan be impacted with significant velocity without fracture, unlikeconventional monolithic ceramic articles.

By unidirectional is meant all the SiC fibers are oriented in eachindividual layer in substantially the same axial direction (±5° ). Byuniaxial is meant that each layer in the composite is oriented such thatall the unidirectionally laid fibers in all layers are oriented insubstantially the same axial direction (±5° ). Note FIG. 1 whichdemonstrates an actual sectional view of a composite containing aplurality of unidirectionally laid SiC fibers in a lithiumaluminosilicate ceramic (LAS) matrix where the composite layers areuniaxially oriented; and FIG. 2 which demonstrates an actual sectionalview of a SiC fiber--lithium aluminosilicate ceramic matrix containing aplurality of unidirectional fiber layers which are multiaxially orientedin the composite--in this case oriented in an alternating 0°/90°multiaxial orientation.

The fracture toughness of this composite system has also been measuredusing a notched beam test with unidirectionally reinforced samplesexhibiting critical stress intensity factor (K_(IC)) values of 19×10³psi (inch)^(1/2) at room temperature (RT); 24×10³ psi (inch)^(1/2) at800° C.; 27×10³ psi (inch)^(1/2) at 1000° C.; and 18×10³ psi(inch)^(1/2) at 1100° C. These values are only slightly less than somealuminum alloys possess. Even the cross-plied (0°/90°) LAS/SiC yarncomposites exhibit K_(IC) values of over 11×10³ psi (inch)^(1/2) from RTto 1100° C. Monolithic Corning 9608 lithium aluminosilicate, on theother hand, has very low fracture toughness with a K_(IC) ofapproximately 1.3×10³ psi (inch)^(1/2) from RT to 1000° C.

It is particularly noteworthy that, even after initial fracture,composites of the present invention retain a substantial fraction oftheir original untested strength. This resistance to fracture, even inthe presence of initiated damage, is distinctly different from thebrittle nature of conventional ceramic materials.

If a glass matrix is employed, any borosilicate glass which will impartthe described properties can be used with the present invention. Corning7740 (Corning Glass Works) was found particularly suitable to producethe desired component properties. Similarly, Corning 7930 (about 96% bywt. silica), obtained by leaching the boron from a borosilicate glass,and Corning 1723 are the preferred high silica content glass andaluminosilicate glass, respectively. While the borosilicate glass andthe aluminosilicate glass can be used in its as received -325 mesh sizeform, the desired properties for the high silica content glasscomposites can only be satisfactorily fabricated with the glass after ithas been ball-milled in propanol for more than 100 hours. It should alsobe noted that mixtures of the above glasses may also be used, withproperties tailored accordingly.

As with the ceramic matrix, any silicon carbide fiber system with therequisite strength can be used, although a multi-filament siliconcarbide yarn with an average filament diameter up to 50 microns ispreferred and yarn with average filament diameter of 5 to 15 microns isespecially preferred. As stated above, Nippon Carbon Company of Japanproduces such a yarn. If a silicon carbide monofilament is used, atypical silicon carbide monofilament of approximately 140 micronsdiameter is available from AVCO Systems Division, Lowell, Mass. Thisfiber exhibits an average tensile strength of up to 3450 MPa, has atemperature capability of over 1300° C. and is stable in oxidizingenvironments.

While a variety of methods can also be used to produce the glasscomposite components of the present invention, e.g. methodsconventionally used to produce glassware articles, the preferred methodis, as described above, by hot pressing a mixture of the silicon carbidefibers and powdered glass. As with the ceramic matrix, this methodprovides particular design flexibility in orienting the fibers, andcomposites formed by such method are particularly well adapted to hotpressing into desired shapes.

In addition to exhibiting excellent fracture toughness and high flexuralstrength, the glass composites of the present invention maintain theseproperties even up to exceptionally high temperatures which makes theiruse particularly suitable in the gas turbine engine. FIG. 3Ademonstrates the exceptional flexural strength of a borosilicateglass-silicon carbide fiber reinforced composite component utilizingsilicon carbide yarn. For a 0°/90° fiber orientation (curve A), flexuralstrengths of over 40,000 psi up to temperatures of about 600° C. wereattained. For 0° fiber orientation (curve B) flexural strengths of over60,000 psi up to temperatures of about 600° C. were attained. And asseen in FIG. 3B, the (0° oriented) silicon carbide fiber monofilamentreinforced borosilicate glass (Corning 7740) composites also exhibithigh flexural strengths above 60,000 psi and as specificallydemonstrated by curves A and B above 75,000 psi for curve A (35% byvolume fiber loading) and above 100,000 psi for curve B (65% by volumefiber loading) which flexural strengths are maintainable at temperaturesup to about 600° C. The 0°/90° silicon carbide fiber orientation in theborosilicate glass matrix produces a flexural strength above about40,000 psi and preferably above about 50,000 psi maintainable totemperatures up to about 600° C.

FIG. 4 demonstrates an exemplary high silica content glass, siliconcarbide fiber (0° oriented) reinforced composite. Curves C and Drepresent lower and upper bounds, respectively, for sample data obtainedwith composites containing between 30% and 40% fiber loading, by volume.These high silica content glass composites show flexural strengths inexcess of 60,000 psi, and preferably in excess of 70,000 psi, even totemperatures up to about 1150° C.

FIG. 5 demonstrates the exceptional flexural strength of analuminosilicate glass-silicon carbide fiber reinforced composite. FIG. 5(fiber loading of 50% by volume) shows for a 0°/90° fiber orientation(curve E) flexural strengths of over 75,000 psi and preferably over100,000 psi maintained to temperatures up to about 700° C.; and for a 0°fiber orientation (curve F) flexural strengths of over 150,000 psi andpreferably over 200,000 psi are maintained to temperatures up to about700° C. Fracture toughness, as measured by a threepoint notched beamtest, results in critical stress intensity factors (K_(IC)) above 15,000psi (inch)^(1/2) for the 0°/90° orientation and above 25,000 psi(inch)^(1/2) for the 0° orientation that are maintained up to about 700°C.

FIG. 6 demonstrates flexural strength of a composite component accordingto the present invention, where unidirectionally reinforced compositesamples (50 volume % SiC), heat-treated after hot-pressing in order tocrystallize the matrix into the β-spodumene (Li₂ O.Al₂ O₃.4SiO₂)structure, have been found to exhibit bend strengths of over 90×10³ psifrom roor temperature to slightly over 1830° F. (1000° C.). Cross-pliedsamoles (0°/90°) have exhibited strengths of over 50×10 psi in the sametemperature range. Monolithic LAS materials, such as Corning 9608,exhibit bend strengths of less than 30×10³ psi from room temperature to1650° F. (900° C.) with very little useful strength (10×10³ psi) at1830° F. (1000° C.). In addition, the steady state creep rate in bendingat an applied stress of 35×10³ psi for an axially reinforced compositehas been measured to be 1.3×10⁻⁵ hr⁻¹ at 1830° F. (1000° C.) with nomeasurable creep below 1650° F. (900° C.).

The mechanical property that ranks as the most impressive for theLAS/SiC system, is its fracture toughness, FIG. 7. As measured by thenotched beam test, axially reinforced samples exhibit K_(IC) (fracturetoughness) values of 15×10³ psi inch^(1/2) at room temperature and22×10³ psi inch^(1/2) at 1830° F. (1000° C.). These values are onlyslightly less than those typical of graphite resin composites and somealuminum alloys. When cross-plied (0°/90°), LAS/SiC composites stillexhibit K_(IC) values of over 8×10³ psi inch^(1/2). Monolithic Corning9608 LAS, on the other hand, has a very low fracture toughness of1.2×10³ psi inch^(1/2). Even hot-pressed Si₃ N₄, which is the toughesthigh temperature monolithic structural ceramic being extensivelyinvestigated for use as a gas turbine component material, has a K_(IC)of only 4-5×10³ psi inch^(1/2).

For forming components with discontinuous silicon carbide fiberreinforcement, the above described fibers are chopped to paper length(e.g. about 1.0 to about 3.0 cm) by any conventional means and formedinto sheets by conventional papermaking techniques. Note copending,commonly assigned U.S. patent application Ser. Nos. 345,996 and 345,998,filed Feb. 5, 1982, the disclosures of which are incorporated byreference.

While the silicon carbide paper used in the samples of the presentinvention was isotropically laid, i.e. substantially equal number offibers in-plane in every direction, the fiber laying can be favored in aparticular in-plane direction in preparation of an article when it isknown that such article will be receiving stress primarily in a singledirection. However, to insure the improved properties of composites ofthe present invention, such favored laying should not exceed about 90%of the total fiber laying, the fibers should be laid in-plane, andaverage fiber length should preferably be about 1 to about 3 cm.

The composite component of the present invention is preferably formed bycutting the formed paper to the desired composite shape followed bypapermaking binder removal, for example by solvent immersion or touchingeach ply to a bunsen burner flame to burn off the binder. The plies arenext either dipped in a slurry of the glass-ceramic or simply stackedwith layers of powdered glass-ceramic sufficient to substantially fillthe spaces between the plies placed between each ply. The formedarticles are then hot pressed at elevated temperature to form thecomposite component as described above.

The processing parameters and composition of the material used can varywidely, depending on the ultimate use of the article. While it is notnecessary to lay the plies in any particular direction, it has beenfound that the best strength properties appear to be obtained when eachindividual ply is laid up in the same direction, i.e. all plies arealigned during lay-up to keep colinear their original orientation withregard to the paper roll axis.

The preferred method for forming the articles of the present inventionis by hot pressing the mixture of silicon carbide fibers andnoncrystalline ceramic powder as mentioned above. This method givesparticular design flexibility in orienting the fibers, and sheets formedby such method are particularly adapted to hot pressing into desiredshapes. An exemplary method comprises continuously unwinding a roll ofsilicon carbide paper from a spool at a moderate rate of speed andpassing such fibers through a slip of the powdered ceramic, solvent andplasticizer to impregnate the sheets. The impregnated sheets can then berewound onto a larger rotating spool. An exemplary slip composition maybe composed of 40 gm of powdered glass ceramic and 780 ml of propanol.An alternative composition may comprise 85 gm of the glass ceramic and200 gm of propanol, 10 gm of polyvinyl alcohol and 5 drops(approximately 1 cc) of a wetting agent such as Tergitol®. The receivingdrum is preferably run at one revolution per minute or linear speed of 5feet per minute (2.54 cm per sec.). Excess glass ceramic and solid canbe removed by pressing a squeegee against the drum as it winds.Preferably the ground ceramic is sized so that 90% of it passes througha -325 mesh sieve. The thus impregnated tape is then dried either atambient temperature or with a radiant heat source to remove solvent.

Following impregnation, the sheets are removed from the drum and cutinto strips to conform to the dimensions of the article to befabricated. In a key processing step, the assembled composite is thenhot pressed either under vacuum or inert gas such as argon in metal diescoated with colloidal boron nitride or graphite dies sprayed with boronnitride powder at pressures of 6.9-13.8 MPa (1000-2000 psi) andtemperatures of 1100° C.-1500° C. Time of hot pressing will varydepending on composite makeup, but generally will be accomplishedbetween about 10 minutes and 1 hour. Additional glass also in powderform may be inserted between each layer as it is laid. SiC fiber loadingin the composite is preferably about 15% to about 50% by volume. Themold can also be vibrated to ensure uniform distribution of the ceramicpowder over the laid fiber surfaces. Processing by starting with thematrix material in the glassy state to permit composite densification byhot pressing, followed by converting the ceramic into the crystallinestate largely contributes to the superior properties of the resultingcomposite. If after hot pressing, any significant portion of the ceramicmatrix material is found to be in the glassy state, further heat treatmay be necessary to substantially completely crystallize the matrix foroptimum high temperature performance. And although it is preferred tohave the ceramic matrix material in the fully ceramic state, acceptablecomposite properties are attainable even if some of the ceramic matrixis retained in the composite in the glass state, e.g. up to 25% byweight.

Based on the composition of the matrix material, the particular fiberreinforcement, and the process of forming the composite, an article withexceptional high strength, fracture toughness, and oxidation resistanceespecially at high temperatures is obtained.

It is particularly noteworthy that, even after initial fracture,composite components of the present invention should retain asubstantial fracture of their original untested strength. Thisresistance to fracture, even in the presence of initiated damage, isdistinctly different from the brittle nature of conventional ceramicarticles.

Typical discontinuous fiber reinforced composite components according tothe present invention are shown in FIGS. 8 and 9. FIG. 8 shows a topview in crosssection of an actual discontinuous silicon carbide fiberreinforced glass-ceramic matrix composite component according to thepresent invention, and FIG. 9 shows a fracture surface of an actualdiscontinuous silicon carbide fiber reinforced glass-ceramic matrixcomposite component according to the present invention.

While the components of the present invention can be used in anysuitable area of the gas turbine engine, their primary utility is inthose areas of the engine which see temperatures over about 500° C. upto about 1300° C., which consists primarily of the core engine.Accordingly, by core engine components is meant any component in the gasturbine engine which will be subjected to temperatures overapproximately 500° C.

Representative core engine components include those in the compressorsection of the gas turbine, the turbine section, the combustor sectionand the after-burner (augmentor) section. Examples of such componentsinclude: blades--both compressor and turbine; vanes--both compressor andturbine; disks to retain the above mentioned blades or ceramic or metalblades; sideplates to prevent inefficient air bleed through turbinestages; abradable outer air seal shoes; combustor liners; afterburnerinternal flaps and seals; and burner and turbine case structures as wellas other thin walled structures subjected to high temperatures.

FIGS. 11 through 13 show some of these applications as follows: FIG. 11shows blades, vanes and seals; FIG. 12 shows augmentor flaps and seals;and FIG. 13 shows combustor liner segment panels.

An augmentor divergent seal test coupon was made and tested todemonstrate the improved components described herein. A 0/90 cross plyreinforced 3.7"×1"×0.2" plate of this material (shown in FIG. 10A) wasground base engine tested in the augmentor duct of a P&WA F-100 engine.Riveted to a metal divergent seal, this component saw a total of 331engine hours, 2459 thermal cycles and 16.7 hours of maximum augmentedthrust at temperatures in excess of approximately 1600° F. (871° C.).Despite the fact that one of the metal rivets and a neighboring metalfitting failed during this test, the composite specimen survivedessentially unscathed (shown in FIG. 10B). Only slight surface damagewas sustained when the remaining metal rivet was removed using a chiseland hammer, thus indicating in an unplanned manner the ability tosurvive severe impact.

The composite material strength, both hot and cold, and stability bothin distortion and oxidation resistance, coupled with high fracturetoughness make the components of the present invention particularlyuseful in this environment. For example, graphite epoxy materials aregenerally not useful above 200° C. and graphite glass composites areusually impractical in environments which see temperatures above 350° C.As such, the components of the present invention are far superior toanything previously attempted in this environment.

The materials of the present invention also provide a wide variety ofchoice of matrix material based on the particular engine temperaturethat the components will encounter. For example, if only temperatures upto about 600° C. will be seen by the components, the glass matrix, andparticularly the borosilicate glass will be suitable. At usetemperatures up to 700° C., the aluminosilicate glass can be used. Andat component temperatures of up to about 1300° C. the high silicacontent glass and the glass-ceramic matrix materials can be used. Ofcourse, matrices suitable for components which will see the highertemperatures would naturally also be suitable for use in the lowertemperature environments.

Although the invention has been shown and described with respect todetailed embodiments thereof, it should be understood by those skilledin the art that various changes and omissions in form and detail may bemade therein without departing from the spirit and scope of theinvention.

We claim:
 1. A gas turbine engine core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising a silicon carbide fiber reinforced glass composite consisting essentially of about 30% to about 70% by volume silicon carbide fibers in a glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass and mixtures thereof, the composite having a fracture toughness exemplified by a critical stress intensity factor above about 15,000 psi (inch)^(1/2), high temperature strength, high temperature oxidation stability and insulating properties.
 2. The component of claim 1 wherein the silicon carbide fiber containing layers are uniaxially oriented.
 3. The component of claim 1 wherein the silicon carbide fiber containing layers are multiaxially oriented.
 4. The component of claim 3 wherein the fibers are oriented to 0°/90°, 0°/±45°/90°, or 0°/30°/60°/90° orientation.
 5. The component of claim 1 wherein the silicon carbide fibers comprise a multiflament silicon carbide yarn with an average filament diameter of up to 50 microns.
 6. The component of claim 5 wherein the yarn has an averge filiment diameter of 5 microns to 15 microns.
 7. The component of claim 1 wherein the silicon carbide fibers are present in an amount of at least about 40% by volume.
 8. The composite of claim 1 having a flexural strength above about 60,000 psi up to a temperature of about 600° C.
 9. The composite of claim 1 wherein the fibers have a substantially 0°/90° orientation within the composite.
 10. The composite of claim 9 wherein the silicon carbide fiber is present in an amount about 50% by volume.
 11. The component of claim 1 having a flexural strength above about 150,000 psi at temperatures up to about 700° C.
 12. The component of claim 1 having a fracture toughness above about 25,000 psi (inch)^(1/2).
 13. A gas turbine engine core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising about 15% to about 50% by volume high strength and high modulus of elasticity discontinuous silicon carbide fibers laid up in substantially in-plane random orientation in a glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass, and mixtures thereof, so as to produce strength and fracture toughness properties greater than that of the glass matrix at temperatures in excess of 300° C. in an oxidizing environment.
 14. The component of claim 13 having a flexural strength greater than 10,000 psi (68.8 MPa) at temperatures in excess of 300° C. in an oxidizing environment.
 15. The component of claim 13 having a flexural strength greater than 20,000 psi (138 MPa) at temperatures in excess of 300° C. in an oxidizing environment.
 16. The component of claim 13 having a fracture toughness greater than 3 MPa/m^(3/2) at temperatures in excess of 300° C. in an oxidizing environment.
 17. The component of claim 13 having a fracture toughness greater than 5 MPa/m^(3/2) at temperatures in excess of 300° C. in an oxidizing environment.
 18. A gas turbine engine core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising about 15% to about 50% by volume high strength, high modulus of elasticity silicon carbide fibers having an average length of about 1 cm to about 3 cm laid up in substantially in-plane random orientation in a low coefficient of thermal expansion glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass and mixtures thereof, producing a composite with flexural strength and fracture toughness properties greater than the glass matrix at elevated temperatures.
 19. A gas turbine engine core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, consisting essentially of about 15% to about 50% by volume high strength and high modulus of elasticity discontinuous silicon carbide fibers laid up in substantially in-plane random orientation in a substantially titanium-free glass-ceramic matrix selected from the group consisting of lithium aluminosilicate, magnesium aluminosilicate, barium aluminosilicate, aluminosilicate, and combinations thereof, so as to produce strength and fracture toughness properties greater than that of the matrix at temperatures in excess of 800° C. in an oxidizing environment.
 20. The component of claim 19 having a flexural strength greater than 10,000 psi (68.8 MPa) at temperatures in excess of 800° C. in an oxidizing environment.
 21. The component of claim 19 having a flexural strength greater than 20,000 psi (138 MPa) at temperatures in excess of 800° C. in an oxidizing environment.
 22. The component of claim 19 having a fracture toughness greater than 3 MPa/m^(3/2) at temperatures in excess of 800° C. in an oxidizing environment.
 23. The component of claim 19 having a fracture toughness greater than 5 MPa/m3/2 at temperatures in excess of 800° C. in an oxidizing environment.
 24. A gas turbine engine core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, consisting essentially of about 15% to about 50% by volume high strength, high modulus of elasticity silicon carbide fibers having an average length of about 1 cm to about 3 cm laid up in substantially in-plane random orientation in a substantially titanium-free glass-ceramic matrix of lithium aluminosilicate, magnesium aluminosilicate, barium aluminosilicate, aluminosilicate, and combinations thereof, producing a composite with flexural strength and fracture toughness properties greater than the ceramic matrix at elevated temperatures.
 25. A gas turbine engine containing at least one core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising a silicon carbide fiber reinforced glass composite consisting essentially of about 30% to about 70% by volume silicon carbide fibers in a glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass and mixtures thereof, the composite having a fracture toughness exemplified by a critical stress intensity factor above about 15,000 psi (inch)^(1/2), high temperature strength, high temperature oxidation stability and insulating properties.
 26. A gas turbine engine containing at least one core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising about 15% to about 50% by volume high strength and high modulus of elasticity discontinuous silicon carbide fibers laid up in substantially in-plane random orientation in a glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass, and mixtures thereof, so as to produce strength and fracture toughness properties greater than that of the glass matrix at temperatures in excess of 300° C. in an oxidizing environment.
 27. A gas turbine engine containing at least one core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, comprising about 15% to about 50% by volume high strength, high modulus of elasticity silicon carbide fibers having an average length of about 1 cm to about 3 cm laid up in substantially in-plane random orientation in a low coefficient of thermal expansion glass matrix selected from the group consisting of borosilicate glass, high silica content glass, aluminosilicate glass and mixtures thereof, producing a composite with flexural strength and fracture toughness properties greater than the glass matrix at elevated temperatures.
 28. A gas turbine engine containing at least one core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, consisting essentially of about 15% to about 50% by vo-ume high strength and high modulus of elasticity discontinuous silicon carbide fibers laid up in substantially in-plane random orientation in a substantially titanium-free glass-ceramic matrix selected from the group consisting of lithium aluminosilicate, magnesium aluminosilicate, barium aluminosilicate, aluminosilicate, and combinations thereof, so as to produce strength and fracture toughness properties greater than that of the matrix at temperatures in excess of 800° C. in an oxidizing environment.
 29. A gas turbine engine containing at least one core engine component blade, vane, disk, side plate, seal, combustor liner, flap, burner case structure, or turbine case structure, consisting essentially of about 15% to about 50% by volume high strength, high modulus of elasticity silicon carbide fibers having an average length of about 1 cm to about 3 cm laid up in substantially in-plane random orientation in a substantially titanium-free glass-ceramic matrix of lithium aluminosilicate, magnesium aluminosilicate, barium aluminosilicate, aluminosilicate, and combinations thereof, producing a composite with flexural strength and fracture toughness properties greater than the ceramic matrix at elevated temperatures. 